Fig. Fig. 23: Compress the tensioner in a vise and lock in place with a pin or Allen wrench

The engine uses a single cam belt drive system with a serpentine type belt. The left side of the engine uses a hydraulic cam belt tensioner which is self-adjusting.

It is recommended that the timing belt be replaced every 60,000 miles (96,618 km).

Disconnect the negative battery cable.

Position the No. 1 piston to TDC of its compression stroke.

Remove the engine drive belts.

Remove the timing belt covers.

Align the camshaft sprockets so each sprocket notch aligns with the cam cover notches. Align the crankshaft sprocket top tooth notch, located at the rear of the tooth, with the notch on the crank angle sensor boss. Mark the three alignment points as well as the direction of cam belt rotation.

Loosen the tensioner adjusting bolts. Remove the bottom three idlers, the cam belt and the cam belt tensioner. The cam sprockets can then be removed with a modified camshaft sprocket wrench tool.

Remove the sprockets, if necessary. Note the reference sensor at the rear of the left cam sprocket.

To install:

Install the sprockets, if removed and torque the retaining bolts to 47-54 ft. lbs. (64-74 Nm).

Install the crankshaft sprocket and the non-adjustable right side idler. Do not install the tensioner idler at this time.

Compress the hydraulic tensioner in a vise slowly and temporarily secure the plunger with a pin or suitable Allen wrench. Install the tensioner and the pulley with the adjustable idler pulley. Temporarily tighten the tensioner while the tensioner is pushed to the right.

Align the crankshaft sprocket notch on the rear sprocket tooth with the crank angle sensor boss. This places the sprocket notch in the 12 o'clock position.

Align the camshaft sprockets with the notches in the cam rear belt cover. This places the sprocket notch in the 12 o'clock position for each camshaft.

Loosen the tensioner retaining bolts and slide the tensioner to the left. Tighten the mounting bolts.

After verifying the timing marks are correct, remove the stopper pin from the tensioner.

Verify the correctness of the timing by noting that the notches on the 2 cam pulleys and the notch on the crankshaft pulley all point to the 12 o'clock position when the belt is properly installed.

Complete the engine component assembly by installing the cam belt covers, the crankshaft pulley bolt and pulley and the remaining components.

Connect the negative battery cable.

2.5L Engine

The engine uses a single cam belt drive system with a serpentine type belt. The left side of the engine uses a hydraulic cam belt tensioner which is self-adjusting.

It is recommended that the timing belt be replaced every 60,000 miles (96,618 km).

Disconnect the negative battery cable.

Disconnect the radiator electric fan motor wiring connectors.

Remove the coolant reservoir tank.

Remove the four bolts that secure the radiator shroud and remove the fan assembly.

Position the No. 1 piston to TDC of its compression stroke.

Remove the engine drive belts.

Remove the A/C compressor drive belt tensioner.

Using holding tool ST499977000 or equivalent, remove the bolt that secures the crankshaft sprocket and remove the sprocket.

Remove the left, right then the center timing belt covers.

Align the camshaft sprockets so each sprocket notch aligns with the rear cover notches. Align the crankshaft sprocket top tooth notch, located at the rear of the tooth with the notch. The crankshaft notch will be at 12 o'clock and the keyway will be at 6 o'clock.

Mark the sprocket alignment points as well as the direction of cam belt rotation for reinstallation purposes if the belt is to be reused.

Loosen the tensioner adjusting bolts.

Remove the lower timing belt idler.

Remove the timing belt from the pulleys.

WARNING

After the timing belt is removed, DO NOT rotate the camshaft sprockets or the crankshaft. Severe internal damage will result from the valve and/or piston contact.

Inspect the timing belt and tensioner for wear or damage and replace as necessary.

Inspect the timing belt tensioner as follows:

When compressing the pushrod of the tensioner with a force of 33 lbs. (147 N), the tensioner should not sink.

When compressing the pushrod of the tensioner with a force of 33-110 lbs. (147-490 N), the tensioner should not sink within 8.5 seconds.

Measure the extension of the rod beyond the body of the tensioner for a length of 0.606-0.646 in. (15.4-16.4mm). If not within specifications, replace the tensioner.

Check the idler sprockets for smooth operation. Replace as necessary.

Using a press, compress the tensioner gradually, taking three minutes or more, and insert a 0.059 in. (1.5mm) pin to secure the rod.

Install the tensioner and the pulley with the adjustable idler pulley. Temporarily tighten the tensioner while the tensioner is pushed to the right.

Align the crankshaft sprocket notch on the rear sprocket tooth with the crank angle sensor boss. This places the sprocket notch in the 12 o'clock position and the and the key way at the 6 o'clock position.

Align the camshaft sprockets with the notches in the cam rear belt cover. This places the sprocket notch in the 12 o'clock position for each camshaft.

Install the timing belt in a clockwise direction starting at the crankshaft with the directional mark and alignment marks properly positioned (if belt was reused).

De-adjust the tension adjuster fully and install a belt adjuster stopper, 13082AA0000, or the equivalent. Using a syringe fill the adjuster with engine oil until the boot overflows. Install a new plug screw.

Align the timing mark on the camshaft pulley with the notch in the timing belt rear cover.

Install the tensioner and spring and the mounting bolts. Push the tension down fully and tighten the mounting bolts.

Install the outer crankshaft sprocket.

Install the timing belt in the correct direction of rotation.

Loosen the tensioner mounting bolts on the number 1 cylinder about 1/2 turn and allow the tensioner pulley to contact the belt.

Tension the belt with a belt tensioner and tighten the tension mounting bolts to 18 ft. lbs. (25 Nm).

Verify all timing marks are in alignment.

Install the three timing belt covers.

Install the dipstick tube.

Connect the electrical connector to the oil pressure switch.

Install the crankshaft pulley.

Install the water pump pulley and pulley mounting bolts.

Install the drive belt and tension to specification.

Tighten the water pump pulley mounting bolts.

Connect the negative battery cable.

3.3L Engine

See Figure 28

Fig. Fig. 28: Timing belt routing and alignment marks-3.3L engine

Disconnect the negative battery cable.

Remove the timing belt covers.

Matchmark the timing belt to the sprocket, cover and block marks as follows:

Turn the crankshaft to align the timing marks on the crankshaft sprocket with the mark on the block.

With the crankshaft marks aligned make sure the left and right camshaft sprocket marks are lined up with marks on the timing covers.

If all the marks are in line, use white paint to mark the direction of rotation of the belt as well as mark the spots on the belt where it crosses over the timing marks on the pulleys.

Loosen the belt tensioner bolts.

Remove belt idler pulley No. 1.

Remove belt idler pulley No. 2.

Remove the timing belt.

Remove the tensioner pulley bolt and remove the tensioner pulley.

Remove the two bolts and the tensioner assembly.

Remove the left side camshaft mounting bolt. To keep the camshaft from turning use camshaft sprocket wrench 499207100 or equivalent. Remove the sprocket.

Remove the right side camshaft mounting bolt. To keep the camshaft from turning use camshaft sprocket wrench 499207100 or equivalent. Remove the sprocket.

Remove the crankshaft sprocket.

To install:

Install the crankshaft sprocket.

Install the right side camshaft sprocket and mounting bolt. Tighten the mounting bolt to 29 ft. lbs. (39 Nm).

Install the left side camshaft sprocket and mounting bolt. Tighten the mounting bolt to 29 ft. lbs. (39 Nm).

Insert a 0.059 in. (1.5mm) diameter stopper pin into place while pushing the tension adjuster rod into the tensioner body.

Install the tensioner and tighten the bolts to 18 ft. lbs. (24 Nm), while the tensioner is pushed all the way to the right.

Install the tensioner pulley and mounting bolt. DO NOT tighten the idler pulley bolt completely.

Make sure the crankshaft and both camshaft sprockets are still lined up with their respective timing marks.

Install the timing belt onto the sprockets with the direction of rotation arrow in the correct direction and the timing marks on the belt in line with the marks on the sprockets.

Install the number 1 and 2 idler pulleys and tighten the mounting bolts to 29 ft. lbs. (39 Nm).

Loosen the tensioner pulley bolt and the tensioner assembly mounting bolts. Slide the tensioner assembly all the way to the left and tighten the bolts to 18 ft. lbs. (24 Nm).

Check again that all the timing marks are still in alignment. If they are remove the stopper pin from the tensioner assembly.

Install the timing belt covers.

Connect the negative battery cable.

ADJUSTMENT

A timing belt should not be viewed as an adjustable component. It is very highly recommended that a timing belt be replaced any time its tension is released.

The timing belt's tension cannot be increased to compensate for wear. If the engine has been disassembled for mechanical work, a new timing belt should always be installed. The small cost of a new timing belt is cheap insurance against expensive engine damage caused by the failure of a re-used timing belt.